Customized High-Pressure Sensor Solution: How Kunlun Zhongda Tackled Otto Electric's Unique Laboratory Requirements
author: jennie
2025-12-22
In the field of precision measurement in laboratories, the selection of high-pressure sensors is often a critical factor affecting experimental accuracy and safety. On September 18, 2014, the technical team of Shenyang Otto Electric Co., Ltd. approached Kunlun Zhongda with a special request—they needed a customized sensor capable of withstanding extreme pressure environments of 200 MPa, while none of the existing products on the market could meet the stringent requirements of their specialized laboratory. This ongoing collaboration not only resolved the customer's technical challenges but also demonstrated the deep value of industrial sensor enterprises transitioning from "standard manufacturing" to "scenario innovation."
I. Tracing the Demand: Industrial pressure measurement sensors Tackle High-Pressure Measurement Challenges in Specialized Laboratories
Otto Electric's laboratory is responsible for prototype testing of ultra-high-voltage equipment in the national power grid. Its pressure monitoring environment exhibits three distinctive characteristics:
Severe Fluctuations in Pressure Peaks: Transient pressure fluctuations range from 180 to 200 MPa.
High Media Compatibility Requirements: Must withstand dual corrosion from special hydraulic oils and insulating gases.
Limited Installation Space: The equipment cavity allows only sensors with a diameter of ≤25 mm.
High Media Compatibility Requirements: Must withstand dual corrosion from special hydraulic oils and insulating gases.
Limited Installation Space: The equipment cavity allows only sensors with a diameter of ≤25 mm.
"We have contacted many sensor suppliers," recalled Otto Electric's Technical Director, "but most could only offer modifications to standard products. Kunlun Zhongda's industrial pressure measurement sensor technical team was the only partner willing to delve into the laboratory scenario for joint development."
In the conventional industrial pressure measurement sensor product line, 200 MPa is already approaching the limit of standard products' range, and Otto Electric's additional requirements for long-term stability and dynamic response speed pushed the technical difficulty to a new level. Kunlun Zhongda's team fully understood that this was not only a challenge of product parameters but also a comprehensive test of system design capability for high-pressure measurement solutions.
II. Technological Breakthrough: How Explosion-proof pressure transducer Design Principles Enabled the 76-Day Journey from Concept to Product
Upon receiving the request, Kunlun Zhongda formed a dedicated team comprising experts in materials engineering, structural design, and signal processing. Three key technical bottlenecks were overcome during the research and development process:
1. Reconstruction of the Sensing Core
Traditional high-pressure sensors are prone to nonlinear drift above 150 MPa. The team innovatively adopted a composite structure of polysilicon strain gauges and diamond coatings, optimizing stress distribution through finite element analysis. This reduced the nonlinear error to within ±0.05% FS across the 200 MPa full-scale range.
Traditional high-pressure sensors are prone to nonlinear drift above 150 MPa. The team innovatively adopted a composite structure of polysilicon strain gauges and diamond coatings, optimizing stress distribution through finite element analysis. This reduced the nonlinear error to within ±0.05% FS across the 200 MPa full-scale range.
2. Revolution in Sealing Structure
To address media penetration issues in high-pressure environments, the R&D team designed a three-tier sealing system:
To address media penetration issues in high-pressure environments, the R&D team designed a three-tier sealing system:
-
Primary Seal: Modified PTFE lip seals
-
Secondary Protection: Nano-ceramic coating covering the sensing chip
-
Tertiary Safeguard: Laser-welded 316L stainless steel housing
3. Adaptation of Special Threads
To meet the installation requirements for M20×1.5 internal threads, the team developed a thin-wall thread machining process, reducing the sensor mounting flange thickness to 3.2 mm while ensuring strength.
To meet the installation requirements for M20×1.5 internal threads, the team developed a thin-wall thread machining process, reducing the sensor mounting flange thickness to 3.2 mm while ensuring strength.
During the above technical development, Kunlun Zhongda's explosion-proof pressure transducer design experience played a critical role. Although Otto Electric's laboratory environment is not a typical hazardous area, the potential impact risk from high-pressure fluid media leakage led to the adoption of explosion-proof pressure transducer housing design and pressure relief channel layout concepts being incorporated into the sensor's safety design. This cross-scenario technology transfer reflects the flexibility and technical depth of Kunlun Zhongda's high-pressure measurement solutions.
III. Validation of Results: How High-pressure measurement solutions Evolved from Single-Unit Testing to Batch Application
In December 2014, the first batch of KZY-KO-HAG high-pressure sensors was delivered to Otto Electric's laboratory. During the 90-day validation period, the sensors underwent:
Pressure Cycling Tests: Completed 500,000 cycles of 0–200 MPa pressure alternation experiments.
Environmental Adaptability Verification: Maintained an accuracy class of 0.1 across a temperature range of -40°C to 125°C.
Long-Term Stability Monitoring: Zero-point drift remained below 0.02% FS during 2,000 hours of continuous operation.
Environmental Adaptability Verification: Maintained an accuracy class of 0.1 across a temperature range of -40°C to 125°C.
Long-Term Stability Monitoring: Zero-point drift remained below 0.02% FS during 2,000 hours of continuous operation.
Experimental data showed that the sensors outperformed imported counterparts in key metrics:
-
Overload capacity reached 300% of the rated pressure.
-
Thermal zero-point drift coefficient was below 0.005%/°C.
-
Dynamic response time was less than 1 ms.
"This industrial pressure measurement sensor not only solved the measurement challenge," stated Otto Electric's Project Manager, "but its modular design also improved our equipment maintenance efficiency by 60%."
As an extended application of explosion-proof pressure transducer technology accumulation, the sensor's safety design concepts have been successfully applied to subsequent high-pressure measurement scenarios in multiple industrial sites. Kunlun Zhongda is systematizing the high-pressure measurement solutions validated through this collaboration, forming reusable technical modules to provide rapid response capabilities for more extreme pressure measurement requirements.
IV. Industry Insight: The Technical System Behind Customization Capabilities—High-pressure measurement solutions
Kunlun Zhongda is committed to providing comprehensive high-pressure measurement solutions, covering the complete chain from sensor selection, installation adaptation, to data acquisition and system integration. For Otto Electric's special requirements, the high-pressure measurement solutions provided by Kunlun Zhongda included not only sensor hardware but also installation process guidance, signal conditioning solutions, and long-term stability calibration recommendations.
Kunlun Zhongda's ability to respond quickly to unique demands stems from its three-tier technical support system:
Fundamental Research Platform: Collaborates with Tsinghua University's School of Materials Science to establish a laboratory for sensors in extreme working conditions.
Rapid Prototyping Capability: Features a 72-hour quick-response process from design to prototype production.
Testing and Validation System: Independently developed specialized testing platforms, including explosion impact and high-frequency vibration tests.
V. Expanded Applications: Explosion-proof pressure transducers and Industrial pressure measurement sensors Product Matrix—From Laboratories to Industrial Sites
Building on this collaboration experience, Kunlun Zhongda has developed a high-pressure sensor product matrix:
KZY-KO Series: Covers pressure ranges from 50 to 400 MPa.
Explosion-Proof Variants: Certified by ATEX/IECEx.
Wireless Transmission Versions: Supports 4–20 mA/HART dual-mode output.
Explosion-Proof Variants: Certified by ATEX/IECEx.
Wireless Transmission Versions: Supports 4–20 mA/HART dual-mode output.
Currently, this technology has been extended to over 20 industrial scenarios, including oil and gas well control and supercritical unit monitoring.
It is worth noting that Kunlun Zhongda's explosion-proof pressure transducer series products also demonstrate outstanding performance in typical hazardous environments such as petrochemical and coal mining safety applications. The explosion-proof pressure transducer ensures safe and reliable pressure measurement in flammable and explosive environments through dual safeguards of explosion-proof housing design and intrinsically safe circuits.
VI. Future Outlook: Sensor Evolution in the Era of Digital Twins
With the wave of smart laboratory construction, Kunlun Zhongda is transforming the know-how accumulated from this collaboration into digital assets:
Establishing a High-Pressure Measurement Database: Contains over 100,000 sets of operational data.
Developing Predictive Maintenance Algorithms: Uses sensor characteristic parameters to predict system risks.
Building a Virtual Calibration System: Reduces physical calibration costs by 70%.
Developing Predictive Maintenance Algorithms: Uses sensor characteristic parameters to predict system risks.
Building a Virtual Calibration System: Reduces physical calibration costs by 70%.
"True innovation is not about manufacturing more precise sensors but about creating measurement systems that better understand scenarios," summarized Kunlun Zhongda's Vice President of Technology. "Our collaboration with Otto Electric proves that when technical teams deeply integrate into customer scenarios, the boundary between standardized products and customized needs becomes blurred—and this is precisely the core competitiveness of industrial pressure measurement sensors in the Industry 4.0 era."
VII. Find a Trusted Sensing Partner for Your Industrial Pressure Measurement Needs
Whether it is precision high-pressure measurement in laboratories, explosion-proof pressure monitoring in industrial sites, or full-system high-pressure measurement solution deployment, Kunlun Zhongda can provide you with full-process professional services from requirement research, solution design, to delivery verification.
Our Core Capabilities Include:
-
Industrial pressure measurement sensors: Covering a wide range of 50-400 MPa, meeting various industrial scenarios
-
Explosion-proof pressure transducers: ATEX/IECEx certified, suitable for flammable and explosive environments
-
High-pressure measurement solutions: Complete pressure measurement ecosystem from sensors to systems
Inquire Now: Start Your Customized Pressure Measurement Journey
📞 Call Technical Hotline: 13220160485
📧 Send Your Requirements: wangweisu@klsensor.com
🖱️ Click Online Customer Service to Chat with Our Technical Engineers in Real Time
Your one request could be the opening chapter of Kunlun Zhongda's next high-pressure measurement benchmark case.
Every measurement deserves to be trusted.
View more from YouTube.
Customer-Driven Innovation: How Kunlun Zhongda Won Deep Collaboration with Beijing Sanbang Rongxun Through Word-of-Mouth
Rapid Response and Professional Matching: How Shanghai Nandao Industrial Achieved System Upgrades Through Kunlun Zhongda's WZPK/P-430 Temperature Sensor
Related Article
The Kunlun Zhongda high temperature and humidity transmitters are the key hardware foundation for transitioning wood drying kilns from experience-based drying to precision drying. The high temperature adaptability, anti-condensation design, and industrial grade stability directly determine the intelligence level of the drying process and the quality of the final product.
Application of Kunlun Zhongda High Temperature and Humidity Transmitter in Wood Drying Kilns
The deep value of screw pump temperature sensors lies not in single point measurement but in a four-in-one system including transient protection, stator smart algorithm, triangular fusion diagnostics and SIL functional safety, which enable most component suppliers to upgrade to system solution providers.
Applications of Temperature Sensors in Screw Pumps
From passive alarm to proactive prediction, from single-point measurement to multi-parameter fusion, that is the technical foundation for the shift from "scheduled maintenance" to "predictive maintenance" by using temperature sensors in multistage high pressure pumps.
Application of Temperature Sensors in Multistage High Pressure Pumps
The value of temperature sensor monitoring lies not in "knowing the current temperature" but in "predicting what it will become"，from passive alarm to proactive prediction, this is the technical foundation of the shift from scheduled to predictive maintenance.
Application of Temperature Sensors in Centrifugal Pumps